Delivering a Class 0 Oil-Free System for a Cleanroom Facility
Project Overview
Design Air recently delivered a complete Class 0 oil-free compressed air system for a client operating a highly sensitive cleanroom facility. The client required absolute air purity to prevent product contamination during manufacturing.
Our engineering team designed, specified, supplied, installed, and commissioned the entire network. We focused on achieving 100% oil-free air while keeping long-term electrical energy costs strictly controlled.
The Challenge: Strict Purity vs. Lifecycle Costs
The primary challenge for this project was ensuring a continuous supply of ISO 8573-1 Class 0 compressed air to eliminate any risk of oil or moisture contamination. In cleanroom environments, microscopic oil aerosols or water droplets can cause immediate product failure and costly rejections.
The client needed a system that provided uncompromising contamination control without incurring prohibitive electrical running costs. We had to balance the initial capital expenditure (CAPEX) of specialised oil-free equipment with the operational expenditure (OPEX) over the system’s lifecycle.
The Solution: A Fully Integrated Atlas Copco System
Our engineering team designed a comprehensive, bespoke solution tailored to the rigours of cleanroom operations. We installed an integrated Atlas Copco network featuring water-injected compressors, desiccant drying technology, and a dedicated distribution system:
2 x Atlas Copco AQ15VSD Water Injected Oil Free Compressors
The heart of the system. These units guarantee 100% oil-free air. The Variable Speed Drive (VSD) automatically adjusts the motor speed to exactly match real-time air demand, dramatically cutting energy waste compared to fixed-speed models.
1 x Atlas Copco 250L Galvanised Wet Air Receiver
This tank acts as a buffer for peak demand and includes a bypass and autodrain to safely manage bulk moisture.
2 x Atlas Copco UD75+ Two-in-one Coalescing Filters
To ensure maximum filtration with minimal pressure loss, we installed UD+ filters. These combine two filtration stages into a single housing, lowering the pressure drop and increasing overall energy efficiency.
2 x Atlas Copco CD55+ Desiccant Dryers with Energy Management
These dryers remove water vapour from the compressed air to achieve ultra-low, stable dew points. The integrated energy management system prevents unnecessary regeneration, further reducing power consumption.
2 x Atlas Copco PDp75+ Dry Filters
Provides clean, dry air storage immediately before distribution.
1 x Atlas Copco Galvanised Dry Air Receiver With Bypass
Positioned after the dryers, these particulate filters capture any residual desiccant dust before it can reach the cleanroom.
Atlas Copco Aluminium Pipework System
We installed a 40mm aluminium distribution ringmain with 16 x 15mm stainless steel drops. The smooth internal surface of the aluminium prevents pressure drops and corrosion, while the stainless steel drops meet strict cleanroom hygienic standards.
The Results: Guaranteed Purity and Efficiency
The installation resulted in a highly efficient, 100% oil-free compressed air network that meets all rigorous cleanroom purity standards.
- Guaranteed Air Purity: The Class 0 certification eliminates the risk of oil contamination, providing complete peace of mind and protecting sensitive cleanroom processes and final products.
- Lower Energy Bills: The combination of VSD technology, UD+ filters, and zero-loss pipework reduces electrical consumption significantly, driving down long-term operational costs.
- Reliable Distribution: The new aluminium ringmain and stainless steel drops ensure the air reaches the point of use without pressure loss or particulate contamination.
The Design Air Standard
As Scotland’s compressed air specialists, we ensured the entire installation met the highest professional standards. From initial design to final commissioning, our goal was to deliver a system built for continuous, critical industrial use. This included full compliance with the Pressure Systems Safety Regulations 2000 (PSSR), providing the client with a safe, legal, and highly reliable utility.
If you have a requirement for anything compressed air, nitrogen, low pressure, or vacuum related, please get in touch with us at Design Air to see how we can help.